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Installation and maintenance manual
Manuel d’installation et de maintenance
Installations- und Wartungshandbuch
Manuale di installazione e di manutenzione
Manual de instalación y de mantenimiento
SyScrew Water EVO
CO/HP/RC
English Français Deutsch Italiano Español
444
1567 kW
Water/water Cooled Screw Chillers
Réfrigérateurs Froid Seulement eau/eau à compresseurs à vis
Wassergekulte Wasserkühler mit Schraubenkompressoren
Refrigeratori Solo Freddo acqua/acqua con compressori a vite
Refrigeradores Sólo Frío agua/agua con compresores a tornillo
Part number / Code / Code / Codice / Código: 367236/A
Supersedes / Annule et remplace / Annulliert und ersezt / Annulla e sostituisce /
Anula y sustituye: 367236
Notified Body /Organisme Notifié / Benannte Zertifizierungsstelle /
Organismo Notificato / Organismo Notificado N°. 1115 ”
ISO 9001:2008 certified management system
COSTRUTTORE / MANUFACTURE -
ITALY
BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI
DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO
Gentile Cliente,
Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato.
I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge.
È opportuno che l’utente provveda periodicamente (è consigliato ogni anno) a far verificare da personale qualificato la taratura ed il corretto intervento dei dispositivi di sicurezza montati sul gruppo.
In particolare la taratura della/e valvole di sicurezza dovrebbe essere verificata al banco intercettando opportunamente il circuito e/o il refrigerante e registrando l’avvenuta verifica sulla scheda di manutenzione del gruppo frigorifero (a disposizione dei tecnici CE/PED che eventualmente ne prenderanno visione).
L’utente avrà cura di conservare efficienti ed in buono stato l’evaporatore ed i suoi accessori e provvederà ad eventuali sostituzioni degli stessi con altri di tipo analogo.
In caso di sostituzione, la valvola di sicurezza e i pressostati di alta pressione dovranno avere caratteristiche equivalenti a quelle fornite e rilasciate con certificato CE/PED.
Si consiglia in occasione della verifica delle valvole di sicurezza di far controllare il corretto intervento dei pressostati di alta pressione.
Per informazioni circa le modalità operative, la strumentazione e la scelta di personale qualificato, è possibile contattare IL COSTRUTTORE.
IMPORTANT NOTICE – Maintenance instructions
Please read carefully the following instructions for the maintenance of safety devices fitted on this refrigeration machine.
All safety devices fitted on the machine by MANUFACTURE have been checked and tested in accordance with European Regulations.
The machine has been designed to operate continuously provided it is regularly maintained and operated within the limitations given in the “Installation, Commissioning, Operation and Maintenance Manual”. The unit should be maintained in accordance with the schedule by the operator/customer, backed up regular service and maintenance visit by an authorised service Centre.
It is the responsibility of the owner to provide for these regular maintenance requirements by a competent person. If in any doubt contact your local Service Centre.
In particular, all safety valves where fitted and safety pressure switches should be tested and calibrated.
Where necessary test certificate provided by a certified authority must be retained as a record together with the Maintenance Log.
Date: 18/01/2012
Nazareno Mantovani
Service Director
Table of Contents
1 - FOREWORD
1.1 Introduction ..........................................................................2
1.2 Warranty ..............................................................................2
1.3 Emergency stop/Normal stop ...............................................2
1.4 An introduction to this manual ..............................................2
2 - SAFETY
2.1 Foreword ..............................................................................3
2.2 Definitions ............................................................................4
2.3 Access to the unit ................................................................4
2.4 General precautions..............................................................4
2.5 Precautions against residual risks .........................................4
2.6 Precautions during maintenance operations ..........................5
2.7 Safety labels ................................................................. 6 & 7
2.8 Safety regulations ........................................................ 8 to 10
3 - TRANSPORT, LIFTING AND POSITIONING
3.1 Inspection ..........................................................................11
3.2 Lifting ................................................................................11
3.3 Anchoring ..........................................................................12
3.4 Storage ..............................................................................12
4 - INSTALLATION
4.1 Positioning of the unit .........................................................13
4.2 Spring isolator installation ...................................................13
4.3 Hydraulic connection of the evaporator ...................... 14 & 15
4.4 Hydraulic connection of the condenser ..............................16
4.5 Hydraulic connections .......................................................16
4.6 Connection of water temperature sensors
(on shell and tube evaporator) ...........................................17
4.7 Connection of water temperature sensors
(on shell and tube condenser/s)..........................................18
4.8 Power supply .....................................................................19
4.9 Electrical connections................................................ 19 & 20
5 - START-UP
5.1 Preliminary check ...............................................................20
5.2 Start-up .............................................................................20
5.3 Checking the operation .......................................................20
5.4 Delivery to the customer .....................................................20
6 - CONTROL
6.1 Display ...............................................................................23
6.2 Setpoint .............................................................................25
6.3 Protection and Safety Equipment ........................................26
7 - PRODUCT DESCRIPTION
7.1 Introduction ........................................................................27
7.2 General specifications ........................................................27
7.3 Compressors .....................................................................27
7.4 Refrigeration circuits ..........................................................27
7.5 Water heat exchanger .........................................................28
7.6 Electrical power supply and control system ........................28
7.7 Accessories .......................................................................28
8 - TECHNICAL DATA
8.1 Pressure drops ...................................................................31
8.2 Technical data ........................................................... 33 to 38
8.3 Unit electrical data ..................................................... 39 & 40
8.4 Position of shock adsorbers and weight distribution on supports ....................................41
8.5 Dimensional Drawings ............................................... 43 to 50
8.6 Service spaces ...................................................................51
9 - MAINTENANCE
9.1 General requirements .........................................................52
9.2 Planned maintenance .........................................................52
9.3 Refrigerant charge ..............................................................53
9.4 Compressor .......................................................................53
9.5 Condenser .........................................................................53
9.6 Dehydrating filter ................................................................53
9.7 Sight glass .........................................................................54
9.8 Electronic expansion valve ..................................................54
9.9 Evaporator .........................................................................54
10 - TROUBLESHOOTING
.......................................... 55
11 - SPARE PARTS
11.1 Spare part list.....................................................................56
11.2 Oil for compressors ............................................................56
11.3 Wiring diagrams .................................................................56
12 - DISMANTLING, DEMOLITION AND SCRAPPING
12.1 Generalities ........................................................................57
1
1.1 Introduction
Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems.
These units are designed for cooling water or glycoled water (and for water heating in heat pump models) and are unfit for any purposes other than those specified in this manual.
This manual includes all the information required for a proper installation of the units, as well as the relevant operating and maintenance instructions.
It is therefore recommended to read this manual carefully before installation or any operation on the machine. The chiller installation and maintenance must be carried out by skilled personnel only
(where possible, by one of Authorised Service Centers).
The manufacturer may not be held liable for any damage to people or property caused by improper installation, start-up and/or improper use of the unit and/or failure to implement the procedures and instructions included in this manual.
1.2 Warranty
These units are delivered complete, tested and ready for being operated. Any form of warranty will become null and void in the event that the appliance is modified without manufacturer’s preliminary written authorisation.
This warranty shall apply providing that the installation instructions have been complied with (either issued by manufacturer, or deriving from the current practice), and the Form 1 (“Start-up”) has been filled-in and mailed to manufacturer (attn. After-Sales Service).
In order for this warranty to be valid, the following conditions shall be met:
Q The machine must be operated only by skilled personnel from
Authorised After-Sales Service.
Q Maintenance must be performed only by skilled personnel - from one of Authorised After-Sales Centers.
Q Use only original spare parts.
Q Carry out all the planned maintenance provided for by this manual in a timely and proper way.
Failure to comply with any of these conditions will automatically void the warranty.
1.3 Emergency stop / Normal stop
The emergency stop of the unit can be enabled using the master switch on the control panel (move down the lever).
For a normal stop, press the relevant push-buttons.
To restart the appliance, follow the procedure detailed in this manual.
1.4 An introduction to the manual
For safety reasons, it is imperative to follow the instructions given in this manual. In case of any damage caused by non-compliance with these instructions, the warranty will immediately become null and void.
Conventions used throughout the manual:
DANGER
The Danger sign recalls your attention to a certain procedure or practice which, if not followed, may result in serious damage to people and property.
WARNING
The Warning sign precedes those procedures that, if not followed, may result in serious damage to the appliance.
NOTE
The Notes contain important observations.
USEFUL TIPS
The Useful Tips provide valuable information that optimises the efficiency of the appliance.
This manual and its contents, as well as the documentation which accompanies the unit, are and remain the property of manufacturer, which reserves any and all rights thereon. This manual may not be copied, in whole or in part, without manufacturer’s written authorization.
2
2 - Safety
2.1 Foreword
These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, Low Voltage
Directive 2006/95/EC, Pressure Vessels Directive 2014/68/
EU, Electromagnetic Interference Directive 2004/108/EC, as well as with other regulations applicable in the country of installation. If these provisions are not complied with, the unit must not be operated.
DANGER
DANGER
The unit must be grounded, and no installation and/or maintenance operations may be carried out before deenergising the electrical panel of the unit.
DANGER
Failure to respect the safety measures mentioned above may result in electrocution hazard and fire in the presence of any short-circuits.
DANGER
Inside the heat exchangers, the compressors and the refrigeration lines, this unit contains liquid and gaseous refrigerant under pressure. The release of this refrigerant may be dangerous and cause injuries.
DANGER
The units are not designed to be operated with natural refrigerants, such as hydrocarbons.
Manufacturer may not be held liable for any problems deriving from the replacement of original refrigerant or the introduction of hydrocarbons.
Units are designed and manufactured according to the requirements of European Standard PED 2014/68/EU (pressure vessels directive).
Q The used refrigerants are included in group II (non-hazardous fluids).
Q The maximum working pressure values are mentioned on the unit’s data plate.
Q Suitable safety devices (pressure switches and safety valves) have been provided, to prevent any anomalous overpressure inside the plant.
Q The vents of the safety valves are positioned and oriented in such a way as to reduce the risk of contact with the operator, in the event that the valve is operated. Anyway, the installer will convey the discharge of the valves far from the unit.
Q Dedicated guards (removable panels with tools) and danger signs indicate the presence of hot pipes or components (high surface temperature).
DANGER
The unit must rest on a base which meets the characteristics specified in this manual; a base with inadequate characteristics is likely to become a source of serious injury to the personnel.
WARNING
The unit has not been design to withstand loads and/or stress that may be transmitted by adjacent units, piping and/or structures.
Each external load or stress transmitted to the unit may break or cause breakdowns in the unit’s structure, as well as serious dangers to people. In these cases, any form of warranty will automatically become null and void.
WARNING
The guards of the fans (only for RC units, with remote air exchangers) must be always mounted and must never be removed before de-energising the appliance.
It is the User’s responsibility to ensure that the unit is fit for the conditions of intended use and that both installation and maintenance are carried out by experienced personnel, capable of respecting all the recommendations provided by this manual.
It is important that the unit is adequately supported, as detailed in this manual. Noncompliance with these recommendations may create hazardous situations for the personnel.
The packaging material must not be disposed of in the surrounding environment or burnt.
3
2.2 Definitions
OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she has the responsibility of making sure that all the safety regulations specified in this manual are complied with, along with the national laws in force.
INSTALLER: means the legal representative of the company who has been given by the owner the job of positioning and performing the hydraulic, electric and other connections of unit to the plant: he/she is responsible for handling and properly installing the appliance, as specified in this manual and according to the national regulations in force.
OPERATOR: means a person authorised by the owner to do on unit all the regulation and control operations expressly described in this manual, that must be strictly complied with, without exceeding the scope of the tasks entrusted to him.
ENGINEER: means a person authorised directly by manufacturer or, in all EC countries, excluding Italy, under his full responsibility, by the distributor of product, to perform any routine and extraordinary maintenance operations, as well as any regulation, control, servicing operations and the replacement of pieces, as may be necessary during the life of the unit.
2.3 Access to the unit
The unit must be placed in an area which can be accessed also by OPERATORS and ENGINEERS; otherwise the unit must be surrounded by a fence at not less than 2 meters from the external surface of the machine.
OPERATORS and ENGINEERS must enter the fenced area only after wearing suitable clothing (safety shoes, gloves, helmet etc.).
The INSTALLER personnel or any other visitor must always be accompanied by an OPERATOR.
For no reason shall any unauthorised personnel be left alone in contact with the unit.
2.4 General precautions
The OPERATOR must simply use the controls of the unit; he must not open any panel, other than the one providing access to the control module.
The INSTALLER must simply work on the connections between plant and machine; he must not open any panels of the machine and he must not enable any control.
When you approach or work on the unit, follow the precautions listed below:
Q do not wear loose clothing or jewellery or any other accessory tat may be caught in moving parts
Q wear suitable personal protective equipment (gloves, goggles etc.) when you have to work in the presence of free flames
(welding operations) or with compressed air
Q if the unit is placed in a closed room, wear ear protection devices
Q cut off connecting pipes, drain them in order to balance the pressure to the atmospheric value before disconnecting them,
2 - Safety (continued) disassemble connections, filters, joints or other line items
Q do not use your hands to check for any pressure drops
Q use tools in a good state of repair; be sure to have understood the instructions before using them
Q be sure to have removed all tools, electrical cables and any other objects before closing and starting the unit again
2.5 Precautions against residual risks
Prevention of residual risks caused by the control system
Q be sure to have perfectly understood the operating instructions before carrying out any operation on the control panel
Q when you have to work on the control panel, keep always the operating instructions within reach
Q start the unit only after you have checked its perfect connection to the plant
Q promptly inform the ENGINEER about any alarm involving the unit
Q do not reset manual restoration alarms unless you have identified and removed their cause
Prevention of residual mechanical risks
Q install the unit according to the instructions provided in this manual
Q carry out all the periodical maintenance operations prescribed by this manual
Q wear a protective helmet before accessing the interior of the unit
Q before opening any panelling of the machine, make sure that it is secured to it by hinges
Q do not touch air cooled coils (RC versions) or shell and tube condensers (CO / HP versions) without protective gloves
Q do not remove the guards from moving elements while the unit is running
Q check the correct position of the moving elements’ guards before restarting the unit
Prevention of residual electrical risks
Q connect the unit to the mains according to the instructions provided in this manual
Q periodically carry out all the maintenance operations specified by this manual
Q disconnect the unit from the mains by the external disconnecting switch before opening the electrical board
Q check the proper grounding of the unit before start-up
Q check all the electrical connections, the connecting cables, and in particular the insulation; replace worn or damaged cables
4
Q periodically check the board’s internal wiring
Q do not use cables having an inadequate section or flying connections, even for limited periods of time or in an emergency
Prevention of other residual risks
Q make sure that the connections to the unit conform to the instructions provided in this manual and on the unit’s panelling
Q if you have to disassemble a piece, make sure that it has been properly mounted again before restarting the unit
Q do not touch the delivery pipes from the compressor, the compressor and any other piping or component inside the machine before wearing protective gloves
Q keep a fire extinguisher fir for electrical appliances near the machine
Q on the units installed indoor, connect the safety valve of the refrigeration circuit to a piping network that can channel any overflowing refrigerant outside
Q remove and leak of fluid inside and outside the unit
Q collect the waste liquids and dry any oil spillage
Q periodically clean the compressor compartment, to remove any fouling
Q do not store flammable liquids near the unit
Q do not disperse the refrigerant and the lubricating oil into the environment
Q weld only empty pipes; do not approach flames or other sources of heat to refrigerant pipes
Q do not bend/hit pipes containing fluids under pressure
2.6 Precautions during maintenance operations
Maintenance operations can be carried out by authorised technicians only.
Before performing any maintenance operations:
Q disconnect the unit from the mains with the external disconnecting switch
2 - Safety (continued)
Q place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch
Q make sure that on-off remote controls are inhibited
Q wear suitable personal protective equipment (helmet, safety gloves, goggles and shoes etc.)
To carry out any measurements or checks which require the activation of the machine:
Q work with the electrical board open only for the necessary time
Q close the electrical board as soon as the measurement or check has been completed
Q for outdoor units, do not carry out any operations in the presence of dangerous climatic conditions (rain, snow, mist etc.)
The following precautions must be always adopted:
Q do not scatter the fluids of the refrigeration circuit in the surrounding environment
Q when replacing an eprom or electronic cards, use always suitable devices (extractor, antistatic bracelet, etc.)
Q to replace a compressor, the evaporator, the condensing coils or any other weighty element, make sure that the lifting equipment is consistent with the weight to be lifted
Q in units connected to a air remote condenser, do not access the fan compartment unless you have disconnected the machine by the disconnecting switch on the board and you have placed a warning sign “do not turn on - maintenance in progress”
Q contact manufacturer for any modifications to the refrigeration, hydraulic or wiring diagram of the unit, as well as to its control logics
Q contact manufacturer if it is necessary to perform very difficult disassembly and assembly operations
Q use only original spare parts purchased directly from manufacturer or the official retailers of the companies on the recommended spare parts list
Q contact manufacturer if it is necessary to handle the unit one year after its positioning on site or if you wish to dismantle it.
5
2 - Safety (continued)
2.7 Safety labels
Identification of the refrigerant - External door Identification of the unit - Outside, on the right-hand front column
USARE SOLO
R134a
E
SPECIAL ESTER OIL
USE ONLY
Electrical warning - Aåacent to the master switch
ATTENZIONE !
ATTENTION !
Prima di aprire togliere tensione
CAUTION !
Enlever l’alimentation electrique avant d’ouvrir
ATENCION !
ACHTUNG !
Vor offnen des gehauses hauptschalter ausschalten
Disconnect electrical supply before opening
Cortar la corrente antes de abrir el aparato
Read the instruction on the electrical board
Gravity centre - Base
On the compressor box
DO NOT OPEN THE PANEL
WHILE UNIT IS RUNNING
WARNING
Circuit drain - Outside, on the right-hand front column
ATTENTION!
Don’t leave the unit with water inside hydraulic circuit during winter or when it is in stand by.
ATTENZIONE!
Non lasciare l’unità con acqua nel circuito idraulico durante l’inverno o quando non è funzionante.
ATTENTION!
Ne laissez pas l’unitè avec de l’eau dans le circuit hydraulique pendant l’hiver ou quand elle ne travaille pas.
WARNUNG!
Lassen Sie nicht das Wasser in die Schaltung während des
Winters oder wenn es nicht funktionient.
¡ATENCÍON!
No deje el agua en el circuito hidráulico durante el invierno o cuando no esta trabajando.
Grounding connection on the electrical board, aåacent to the connection
6
Start-up warning - Outside the door of the electrical board
2 - Safety (continued)
Final Test Certificate - Inside the external door
Instruction for the lifting
Warning - Safety valve vents
Warning - High temperature zone aåacent to hot pipes or components
Fitting identification - Aåacent to fittings
EIN - INLET
ENTRÉE - ENTRATA
AUS - OUTLET
SORTIE - USCITA
7
2 - Safety (continued)
2.8 Safety regulations
Toxicity
REFRIGERANT DATA
Low
Contact with skin
SAFETY DATA: R134a
If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited; it may cause a slight irritation, and the liquid is degreasing. Unfreeze the affected skin with water.
Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin. Wash with plenty of warm water the affected skin.
In the presence of symptoms such as irritation or blisters, obtain medical attention.
Contact with eyes
Vapours do not cause harmful effects. The spraying of refrigerant may cause frost burns.
Wash immediately with a proper solution or with tap water for at least 10 minutes, and then obtain medical attention.
Ingestion
Very unlikely - should something happen, it will cause frost burns.
Do not induce vomiting. Only if the patient is conscious, wash out mouth with water and give some
250 ml of water to drink. Then, obtain medical attention.
Inhalation
R134a: remarkable concentrations in the air may have an anaesthetic effect, up to fainting.
The exposure to considerable amounts may cause irregular heartbeat, up to the sudden death of the patient. Very high concentrations may result in the risk of asphyxia, due to the reduction in the oxygen percentage in the atmosphere. Remove the patient to fresh air and keep warm and at rest.
If necessary, give oxygen. In case of breathing difficulties or arrest, proceed with artificial respiration.
In case of cardiac arrest, proceed with cardiac massage. Then, obtain medical attention.
Recommendations
Prolonged exposure
Professional levels
Stability
Conditions to avoid
Hazardous reactions
Hazardous decomposition products
Semiotics or support therapy is recommended. Cardiac sensitisation has been observed that, in the presence of circulating catecholamines such as adrenalin, may cause cardiac arrhythmia and accordingly, in case of exposure to high concentrations, cardiac arrest.
R134a: a study on the effects of exposure to 50,000 ppm during the whole life of rats has identified the development of benign testicle tumour.
This situation should therefore be negligible for personnel exposed to concentrations equal to or lower than professional levels.
R134a: Recommended threshold: 1000 ppm v/v - 8 hours TWA.
R134a: Not specified
Do not use in the presence of flames, burning surfaces and excess humidity.
May react with sodium, potassium, barium and other alkaline metals.
Incompatible substances: magnesium and alloys with magnesium concentrations > 2%.
R134a: Halogen acids produced by thermal decomposition and hydrolysis.
8
2 - Safety (continued)
2.8 Safety regulations (continued)
REFRIGERANT DATA
General precautions
SAFETY DATA: R134a
Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level.
Respiratory system protection
If you are in doubt about the concentration in the atmosphere, it is recommended to wear a respirator approved by an accident-prevention
Authority, of the independent or oxygen type.
Storage
Protective clothing
Cylinders must be stored in a dry and fresh place, free from any fire hazard, far from direct sunlight or other sources of heat, radiators etc.
Keep a temperature below 45 °C.
Wear overalls, protective gloves and goggles or a mask.
Accidental release measures
It is important to wear protective clothing and a respirator.
Stop the source of the leak, if you can do this without danger. Negligible leaks can be left evaporating under the sun, providing that the room is well ventilated.
Considerable leaks: ventilate the room. Reduce the leak with sand, earth or other absorbing substances.
Make sure that the liquid does is not channelled into gutters, sewers or pits where the vapours are likely to create a stuffy atmosphere.
Disposal
The best method is recovery and recycling. If this method is not practicable, dispose according to an approved procedure, that shall ensure the absorption and neutralization of acids and toxic agents.
Fire fighting information R134a: Not flammable in the atmosphere.
Cylinders The cylinders, if exposed to fire, shall be cooled by water jets; otherwise, if heated, they may explode.
Protective fire fighting equipment In case of fire, wear an independent respirator and protective clothing.
9
2 - Safety (continued)
2.8 Safety regulations (continued)
LUBRICANT OIL DATA
Classification Not harmful.
Contact with skin
SAFETY DATA: POLYESTER OIL (POE)
May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day.
It is also recommended to wash your overalls at least once a week.
Contact with eyes
Ingestion
Inhalation
Wash thoroughly with a suitable solution or tap water.
Seek medical advice immediately.
Seek medical advice immediately.
Conditions to avoid
Strong oxidising substances, caustic or acid solutions, excess heat.
May corrode some types of paint or rubber.
Protection of the respiratory system
Protective clothing
Accidental release measures
Disposal
Use in well ventilated rooms.
Always wear protective goggles or a mask. Wearing protective gloves is not mandatory, but is recommended in case of prolonged exposure to refrigerant oil.
It is important to wear protective clothing and, especially, goggles.
Stop the source of the leak. Reduce the leak with absorbing substances (sand, sawdust or any other absorbing material available on the market).
The refrigerant oil and its waste will be disposed of in an approved incinerator, in conformity with the provisions and the local regulations applicable to oil waste.
Fire fighting information
In the presence of hot liquid or flames, use dry powder, carbon dioxide or foam. If the leak is not burning, use a water jet to remove any vapours and to protect the personnel responsible for stopping the leak.
Cylinders The cylinders exposed to a fire will be cooled with water jets in case of fire.
Fire fighting protective equipment In case of fire, wear an independent respirator.
10
3 - Transport, Lifting and Positioning
Refrigerators are supplied assembled (apart from standard antivibrating rubber supports, that will be installed on site). The equipment are full of refrigerant and oil, in the quantity required for a proper operation.
3.1 Inspection
When the unit is delivered, it is recommended to check it carefully and to identify any damage occurred during transportation. The goods are shipped ex-factory, at the buyer’s risk. Check that the delivery includes all the components listed in the order.
In case of damage, note it down on the carrier’s delivery note and issue a claim according to the instructions provided in the delivery note.
In the presence of any serious damage, that does not affect the surface only, it is recommended to inform manufacturer immediately.
Please note that manufacturer may not be held liable for any damage to the equipment during transportation, even though the carrier has been appointed by the factory.
3.2 Lifting
The unit must be lifted by using the hooks inserted into the relevant eyebolts (see the figure).
It is recommended to use a spacer to prevent cables from damaging the unit (see the figure). For sizes equipped with 1 compressor (440-
770) the minimum size of the spacer is 1350 mm. For sizes equipped with 2 compressors (860-1550) the minimum size of the spacer is
1520 mm.
Before positioning the unit, make sure that the place of installation is appropriate and sturdy enough to hold the weight and to withstand the stress caused by the operation of the whole assembly.
WARNING
Do not displace the unit on rollers, and do not lift it with a lift truck.
Unit must be lifted carefully.
To lift unit slowly and regularly.
To lift and displace the unit:
Q Insert and secure eyebolts into the holes marked on the frame.
Q Insert spacer between cables.
Q Hook near the barycentre of the unit.
Q The cables must be long enough to form, if tensioned, an angle of at least 45° with respect to the horizontal plane.
11
3 - Transport, Lifting and Positioning (continued)
WARNING
For lifting operations, use only tools and material fit for this purpose, in accordance with accident-prevention regulations.
WARNING
During the lifting and handling of the unit, be careful not to damage the electrical board, installed on one side of the unit.
The sides of the unit must be protected by cardboard or plywood sheets.
WARNING
It is recommended not to remove the protective plastic envelope, that should prevent scraps from penetrating into the appliance and any damage to the surfaces, until the unit is ready for operation.
3.3 Anchoring
It is not essential to secure the unit to the foundations, unless in areas where there is a serious risk of earthquake, or if the appliance is installed on the top of a steel frame.
3.4 Storage
When the unit is to be stored before installation, adopt a few precautions to prevent any damage or risk of corrosion or wear:
Q plug or seal every single opening, such as water fittings
Q do not store the appliance in a room where the temperature exceeds 50 °C for the units using R134a and, if possible, do not expose to direct sunlight
Q minimum storage temperature is -25 °C
Q it is recommended to store the unit in a roof where traffic is minimized, to prevent the risk of accidental damage
Q the unit must not be washed with a steam jet
Q take away and leave to the site manager all the keys providing access to the control board
Finally, it is recommended to carry out visual inspections at regular intervals.
12
4 - Installation
4.1 Positioning of the unit
DANGER
Before installing the unit, make sure that the structure of the building and/or the supporting surface can withstand the weight of the appliance. The weights of the units are listed in
Chapter 8 of this manual.
These units have been designed for indoor installation on a solid surface. Standard accessories include antivibrating rubber supports, that must be positioned under the base.
When the unit is to be installed on the ground, it is necessary to provide a concrete base, to ensure a uniform distribution of the weights.
As a general rule, no special sub-bases are required. However, if the unit is to be installed on the top of inhabited rooms, it is advisable to rest it on spring shock absorbers (optional), that will minimise the transmission of any vibration to the structures.
To choose the place of installation of the unit, bear in mind to guarantee all the necessary spaces for air circulation and maintenance operations (see Chapter 9).
4.2 Spring Isolator Installation
Q Prepare the base, that must be flat and plane.
Q Lift the appliance and insert shock absorbers as follows:
13
4.3 Hydraulic connection of the evaporator
The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components.
Their installation is mandatory for warranty.
WARNING
4 - Installation (continued)
The external hydraulic circuit must ensure the water flow to the evaporator under any working or adjustment conditions.
A flow switch will stop the unit when the water is not circulating or a flow rate problem occurs.
To install the flow switch, follow the manufacturer’s instructions.
As a general rule, the flow switch shall be mounted on a horizontal pipe, at a distance from the curves equal to 10 times the diameter of the pipe and far from valves or other components that are likely to hinder the water flow upstream of or downstream from the flow switch.
Q The bleed valves must be mounted on the highest point of the piping.
Q
The stop valves must be mounted on the piping of the water entering/leaving the evaporator.
Q The drain points (provided with plugs, cocks etc.) must be arranged in the lowest point of the piping.
The circuit shall be composed by the following elements:
Q
A circulation pump which can ensure the necessary capacity and discharge head.
Q The capacity of the primary hydraulic circuit should not be less than 7.5 litres/KW of cooling capacity, in order to prevent the repeated start-up of the compressor and any damage to it. If the water capacity in the primary piping of the circuit and in the evaporator is lower than this value, an insulated storage tank shall be installed.
Q A membrane expansion vessel provided with safety valve with vent, that must be visible.
NOTE
The capacity of the expansion vessel must allow for an expansion of at least 2% of the volume of the fluid in the circuit (evaporator, piping, user circuit and standby tank, if any). The expansion vessel needs not be isolated, because no water can circulate inside it.
WARNING
The flow switch must be connected (terminals
1-2) as shown in the wiring diagram of the
“User’s Terminal Box”.
14
4 - Installation (continued)
Then:
Q Provide the evaporator with a by-pass circuit equipped with a valve to wash the plant.
Q Insulate the piping, to prevent the risk of heat loss.
Q Position a filter on the suction side of the evaporator of the heat recovery condenser.
Standard hydraulic circuit
Unit External water circuit
Connection Diagram
COMPONENTS
I Pressure gauge connection
S Gate valve
F1 Flow Switch
GA Flexible hoses
R Drain cock
T Thermometer
F Filter
I1/I2 Pressure gauge connection to measure pressure drop or head pressure
WARNING
Before filling the circuit, it is important to check that it is free from any foreign matter, sand, gravels, rust, welding deposits, waste and other materials that may damage the evaporator.
When cleaning the lines, it is recommended to create a circuit bypass. It is important to mount a filtering medium (30 mesh) upstream of the chiller.
NOTE
If necessary, the water required to fill the circuit must be treated to obtain the requested pH.
15
4 - Installation (continued)
4.4 Hydraulic connection of the condenser
WARNING
The external hydraulic circuit must ensure the water flow to the condenser under any working or adjustment conditions.
The cooling of the units is generally ensured by connecting the condenser to a cooling tower, though the units can be cooled also with well water.
In the presence of a water-cooled condenser, it is necessary to check the flow rate and/or the temperature of the cooling fluid that flows through the condenser, so as to maintain the refrigerant pressure at values that can ensure a satisfactory operation.
When a cooling tower is used, the simplest regulation methods consist of checking the operation or the speed of the fan or the air volume, by means of a damper, once the pilot thermostat has been installed in the basin of the tower.
Alternatively, or if no water from a cooling tower is used, you can adopt a recirculaton system provided with a 3-way valve.
This circuit shall consist of:
Q A circulation pump that can ensure the necessary capacity and discharge head.
Q A flow meter to turn off the appliance when no water is circulating.
To install the flow meter, follow the manufacturer’s instructions.
As a general rule, the flow meter shall be mounted on a horizontal pipe, at a distance from the curves equal to 10 times the diameter of the pipe and far from valves or other components that are likely to hinder the water flow upstream of or downstream from the flow meter.
Q The bleed valves must be mounted on the highest point of the piping.
Q The stop valves must be mounted on the piping of the water entering/leaving the condenser.
Q The discharge points (provided with plugs, cocks etc.) must be arranged in the lowest point of the piping.
Furthermore:
Q
Provide the condenser with a by-pass circuit, equipped with a shutoff valve.
Q Insulate piping, to prevent the risk of heat loss.
Q
Install a filter on the suction side of the condenser.
Q A three-way valve should be installed on-site. It permits to bypass the condenser for correct operation at low return water temperature. The best position is close to the condenser.
To install the flow meter, follow the diagram illustrated in paragraph
4.3.
The flow meter must be connected in series, as shown in the wiring diagram of the control panel.
WARNING
4.5 Hydraulic connection
The water inlet/outlet fittings shall conform to the instructions provided by the plates affixed neat the connection points.
16
4 - Installation (continued)
4.6 Connection of water temperature sensors
(on shell and tube evaporator)
The units are provided with fittings for hydraulic connections between heat exchangers and plant.
Each fitting is complete with sensor well to fasten temperature sensor (BT-IN and BT-OUT). Fittings are supplied separate and must be mounted during the installation of the unit.
BT OUT
BT IN
OUT
VICTAULIC JOINT
FITTING
IN
VICTAULIC JOINT
FITTING
17
4 - Installation (continued)
4.7 Connection of water temperature sensors
(on shell and tube condenser/s)
Hydraulic connections between condenser/s and plant are supplied separately and must be installed during the installation of the unit.
Inlet / outlet water temperature probes should be placed inside dedicated water probes pockets to be provided over the installation.
Kit manifold accessory (offered as an option for units equipped with two compressors) is already including water probes pockets.
CONNECTION STANDARD CONNECTION WITH MANIFOLD KIT
BT INGRESSO
BT OUT
BT IN
18
4.8 Power supply
DANGER
DANGER
DANGER
4 - Installation (continued)
Before carrying out any operations on the electrical system, make sure that the unit is deenergised.
It is important that the appliance is grounded.
The company in charge of the installation shall conform to the standards applicable to outdoor electrical connections.
4.9 Electrical connections
The unit must be installed on site according to the Machinery
Directive (2006/42/EC), the Low Voltage Directive (2006/95/EC), the Electromagnetic Interference Directive (2004/108/EC) and the usual procedures and standards applicable in the place of installation.
The unit must not be operated if its installation has not been carried out according to the instructions provided in this manual.
The power supply lines must consist of insulated copper conductors, dimensioned for the maximum absorbed current.
Connection to terminals must be performed according to the diagram of connections (User’s Terminal Box) provided in this manual and according to the wiring diagram which accompanies the unit.
WARNING
Before connecting the power supply lines, check that the available voltage value does not exceed the range specified in the Electric Data (Chapter
8).
The manufacturer may not be held liable for any damage and/or injury caused by failure to comply with these precautions.
The unit conforms to EN 60204-1.
The following connections shall be provided:
Q A 3-phase and grounding connection for the power supply circuit.
Q The electrical distribution system shall meet the power absorbed by the appliance.
Q The disconnecting and magnetothermal switches must be sized to control the starting current of the unit.
Q The power supply lines and the insulation devices must be designed in such a way that every line independent.
Q It is recommended to install differential switches, to prevent any damage caused by phase drops.
Q The fans and compressors are supplied through contactors controlled from the control panel.
Q Each motor is provided with an internal safety thermal device and external fuses.
Q The power supply cables must be inserted into dedicated openings on the front of the unit, and the will enter the electrical board through holes drilled on the bottom of the board.
For 3-phase systems, check also that the unbalance between the phases does not exceed 2%. To perform this check, measure the differences between the voltage of each phase couple and their mean value during operation.
The maximum % value of these differences (unbalance) must not exceed 2% of the mean voltage.
If the unbalance is unacceptable, contact the Energy Distributor to solve this problem.
WARNING
Supplying the unit through a line whose unbalance exceeds the permissible value will automatically void the warranty.
19
Electrical connections
4 - Installation (continued)
20
WARNING
NOTE
The operations carried out by authorised personnel are limited to the start-up of the unit, and do not include any other operation on the plant, such as, for example, electrical and hydraulic connections etc.
All the other operations before start-up, including oil pre-heating for at least 12 hours, must be performed by the Installer.
5.1 Preliminary check
The checks listed below shall be performed before starting the unit and before the arrival of the personnel authorised.
Q Check the section of power supply and grounding cables; make sure that terminals are tightened and check the correct operation of contactors, with the main switch open.
Q Check that any voltage and phase variation in the power supply does not exceed the prefixed thresholds.
Q Connect the contacts of the flow switch and the thermal relay of the pump and of the other devices (if any), to terminals 1-2 and
3-4, respectively.
Q Check that the components of the external water circuit (pump, user equipment, filters, power supply tank and reservoir, if any) have been installed properly, and according to the manufacturer’s instructions.
Q Check the filling of the hydraulic circuits, and make sure that the fluid circulation is correct, without any trace of leaks and air bubbles. If you use ethylene glycol as antifreeze, check that its percentage is correct.
Q Check that the direction of rotation of the pumps is correct, and that fluids have been circulating for at least 12 hours for both pumps. Then, clean the filters on the suction side of the pumps.
Q Adjust the liquid distribution network in such a way that the flow rate is within the specified range.
Q Check that the water quality is up to the specifications.
Q Check that oil heaters, if any, have been turned on at least 12 hours before.
5.2 Start-up
Start-up sequence:
Q Turn on the Main switch (at least 12 hours before).
Q Check that the oil in the compressor has reached the requested temperature (the minimum temperature outside the pan must be approx. 40°C) and that the auxiliary control circuit is energised.
Q Check the operation of all the external equipment, and make sure that the control devices of the plant are properly calibrated.
Q Start the pump and check that the water flow is correct.
Q Set the desired fluid temperature on the control board.
Q Start the appliance (see Chapter 6).
5 - Start-Up
The unit must be started for the first time by personnel suitably trained by one Authorised
Service Centre. Failure to meet this requirement will immediately void the warranty.
Q Check the correct direction of rotation of compressors.
Compressors cannot compress the refrigerant when they rotate in the opposite direction. To make sure that they are rotating in the correct direction, simply check that, just after the start-up of the compressor, the pressure drops on the LP side and rises on the HP side. Furthermore, if a compressor rotate in the opposite direction, there is a considerable rise in the sound level of the unit, as well as in a dramatic reduction of current absorption compared to normal values. In case of wrong rotation, the compressor can be definitely damaged. Phase monitor is assembled in the unit as a standard to prevent wrong compressors rotation.
Q After about 15 minutes of operation check that there are no bubbles, through the sight glass on the liquid line.
WARNING
The presence of bubbles may indicate that a part of the refrigerant charge has been released in one or more points. It is important to remove these leaks before proceeding.
Q Repeat the start-up procedure after removing the leaks.
Q Check the oil level in the compressor’s sight glass.
5.3 Checking the operation
Check the following:
Q The temperature of the water entering the evaporator.
Q The temperature of the water leaving the evaporator.
Q The level of the water flow rate in the evaporator, if possible.
Q The temperature of the water entering the condenser.
Q The temperature of the water leaving the condenser.
Q The level of the water flow rate in the condenser, if possible.
Q The current absorption upon the start of the compressor and in case of stabilised operation.
Check that the condensing and evaporation temperatures, during operation at high and low pressure detected by the pressure gauges of the refrigerant, are within the following range:
(On the units not provided with HP/LP pressure gauges for the refrigerant, connect a pressure gauge to the Shrader valves on the refrigeration circuit).
HP side
Approx. 2 to 7 °C above the temperature of condenser leaving water temperature, for 134a units.
LP side
Approx. 2 to 7 °C below the temperature of the leaving chilled water, for R134a units.
5.4 Delivery to the customer
Q Train the user according to the instructions provided in Section 6.
21
6 - Control
6 General information
Introduction
This document contains the information and the operating instructions for 1/2 screw compressors of step type.
This information is for the after-sales service and the production operators, for the end-of-line testing.
Main characteristics
– Microprocessor control
– User-friendly keyboard
– Proportional control (RWT)
– Neutral zone control on the leaving water temperature (LWT)
– Access code to enter the Manufacturer’s Level
– Access code to enter the Assistance Level
– Alarm and LED
– Backlighted LCD
– Rotation of the compressor operation
– Night mode (or Low Noise) control
– Counting of the pump/compressors’ hours of operation
– Display of discharge and suction pressure values
– Display of temperature sensor
– History of stored alarms (option)
– RS485 serial port to connect the chiller control to a BMS network.
The following accessories can be also connected:
– Remote Display Terminal
– Wire Remote Control.
– Double set point.
The control system consists of: a) Main Board. Units are provided with a microprocessor card which is fully programmed by default for the control of a chiller equipped with a HP transducer and a LP transducer for each circuit.
b) EEV controllers (two separate drivers) to the management of the electronic expansion valves.
C) Keyboard & Display Terminal.
The terminal makes it possible to carry out the following operations:
– the initial configuration of the machine
– the change of all the main operating parameters
– the display of the detected alarms
– the display of all the measured quantities
The terminal and the card are connected by a 6-way phone cable.
The connection of the terminal to the basic card is not essential for the normal operation of the controller.
22
6 - Control (continued)
6.1 Display/Keyboard
Esc key: allows you to move from one mask to another.
Alarm key: used to display the alarms, to reset them in manual.
Press it one to display the mask of the activated alarm, press it again to reset the alarm signal.
+
Prg+Esc keys: Pressing these keys at the same time,allows you to turn the unit on/off.
Up-down keys: allows you to set the control parameters’ values and to move from one mask to another (not backlighted).
Enter key: used to move the cursor inside the masks and to save the values of the set parameters.
Alarm+Enter keys: press these keys at the same time to enter the "storical alarm" after 1’ come back at status machine menu.
The display is an LCD 8 lines x 22 columns. The quantities and the information about the operation of the unit are alternated in the form of subsequent screens, named “masks”.
It is possible to move inside the masks with the terminal keys as described below.
Arrows key - Up/Down/Enter
If the cursor is in the top left-hand corner (Home), press the UP/
DOWN keys to access the subsequent masks associated to the selected branch. If a mask includes some value setting fields and you press the ENTER key, the cursor will reach these fields.
Once you have reached the quantity setting field, you can modify any value (within the expected limits) by pressing the UP/DOWN keys.
After you have selected the desired value, press the ENTER key again to store it.
23
6 - Control (continued)
Alarms
Alarm code Description
56
59
60
61
49
50
52
53
45
46
47
48
41
42
43
44
68
69
70
71
62
63
65
67
37
38
39
40
32
34
35
36
22
23
24
27
18
19
20
21
13
14
16
17
9
10
11
12
7
8
5
6
3
4
1
2
Main board - EPROM Failure
Main board - Clock card Failure
Main board - External air temperature sensor fault
Main board - Return Water temperature sensor fault (evaporator)
Main board - Leaving Water temperature Sys 1 sensor fault (evaporator)
Main board - Leaving Water temperature Sys 2 sensor fault (evaporator)
Main board - Low pressure sys 1 sensor fault
Main board - Low pressure sys 2 sensor fault
Main board - High pressure sys 1 sensor fault
Main board - High pressure sys 2 sensor fault
Main board - Discharge temperature sys 1 sensor fault
Main board - Discharge temperature sys 2 sensor fault
Main board - Return Water temperature sensor fault (condenser)
Main board - Leaving Water temperature sensor fault (condenser)
Serious alarm (SQZ)
Flow switch / Plant interlock
Oil Safety Sys 1 manual reset
Oil Safety Sys 2 manual reset
High pressure switch Sys 1
High pressure switch Sys 2
Low pressure Sys 1 switch manual reset
Low pressure Sys 2 switch manual reset
Thermal protection compressor 1 Sys 1 manual reset
Thermal protection compressor 1 Sys 2 manual reset
Remote condenser Fan Thermal protection Sys 1 (RC version only)
Remote condenser Fan Thermal protection Sys 2 (RC version only)
Low refrigerant cutout Sys 1 manual reset
Low refrigerant cutout Sys 2 manual reset
Low pressure alarm Sys 1 manual reset
Low pressure alarm Sys 2 manual reset
Out of envelope Sys 1 manual reset
Out of envelope Sys 2 manual reset
High pressure Sys 1 manual reset
High pressure Sys 2 manual reset
High limit discharge temperature Sys1 manual reset
High limit discharge temperature Sys2 manual reset
¨7:DWHU7RR+LJK6\V
¨7:DWHU7RR+LJK6\V
Wrong Water Trend Sys 1
Wrong Water Trend Sys 2
Antifreeze alarm manual reset Sys 1
Antifreeze alarm manual reset Sys 2
Plant pump maintenance
Compressor 1 Sys 1 maintenance
Compressor 1 Sys 2 maintenance
Driver 1 LAN disconneted manual reset
Driver 2 LAN disconneted manual reset
EPROM Error Driver 1
EPROM Error Driver 2
Driver 1 S1 Sensor fault
Driver 1 S2 Sensor fault
Driver 2 S1 Sensor fault
Driver 2 S2 Sensor fault
EEV motor Error (Check viring) Sys 1
EEV motor Error (Check viring) Sys 2
Driver 1 Battery alarm
24
Notes
6 - Control (continued)
Alarm code Description
138
139
140
141
142
143
144
159
123
124
127
132
134
135
136
137
160
187
188
90
118
119
122
84
87
88
89
76
79
80
83
72
73
74
75
Driver 2 Battery alarm
Autotune alarm Sys 1
Autotune alarm Sys 2
Low suction alarm Sys 1
Low suction alarm Sys 2
Expansion board 1 OFF LINE
Expansion board 2 OFF LINE
Expansion board 1 - Chillernet sensor fault
Expansion board 1 - 4-20 mA remote set-point fault
Low delta pressure Sys 1 manual reset
Low delta pressure Sys 2 manual reset
Flow switch / Source interlock
Source pump maintenance
Oil Safety Sys 1 auto reset
Oil Safety Sys 2 manual reset
Low pressure Sys 1 switch auto reset
Low pressure Sys 2 switch auto reset
Thermal protection compressor 1 Sys 1 auto reset
Thermal protection compressor 1 Sys 2 auto reset
Fan Thermal protection Group 2 Sys 1 auto reset
Fan Thermal protection Group 2 Sys 2 auto reset
Low refrigerant cutout Sys 1 auto reset
Low refrigerant cutout Sys 2 auto reset
Low pressure alarm Sys 1 auto reset
Low pressure alarm Sys 2 auto reset
Out of envelope Sys 1 auto reset
Out of envelope Sys 2 auto reset
High pressure Sys 1 auto reset
High pressure Sys 2 auto reset
High limit discharge temperature Sys1 auto reset
High limit discharge temperature Sys2 auto reset
Driver 1 LAN disconnected automatic reset
Driver 2 LAN disconnected automatic reset
Low delta pressure Sys 1 auto reset
Low delta pressure Sys 2 auto reset
Notes
6.2 Setpoint
Pressing the Set key allows you to enter the Set point level accessible to the user. The parameters that can be set are listed below, along with the limit values and the default values (standard shop settings):
User parameters
Cooling Setpoint
Heating Setpoint
Cooling Setpoint - glycol water
Proportional band
Neutral band
Languages
System On/Off
System 1 #
System 2 #
Unit management
Control mode
RWT Return Control
LWT Leaving Control
RWT Return Control
LWT Leaving Control
RWT Return Control
LWT Leaving Control
RWT Return Control
LWT Leaving Control
——
——
——
Min value Max value
9
6
25
30
1
1
-5
-8
ITA ENG FRE GER SPA
15
15
10
6
15
15
54
60
OFF
OFF
Cooling
ON
ON
Default
10
8
5
2
ITA
10
8
40
45
OFF
OFF
25
6 - Control (continued)
6.3 Protection and Safety Equipment
Refrigeration system
The units are filled with R134a refrigerant fluid of non hazardous type
(group II). Safety device (pressure switch and safety valves) with the sets below indicated are provided on the discharge and suction line of each circuit.
Discharge Line
Pressure relief valve 22 bar.
Pressure switch 19.8 bar for HP/RC/BC version,
15.5 bar for CO version.
Suction line
Pressure relief valve 14.5 bar.
Pressure switch 0.5 bar.
Frost Protection for the Chilled Fluid
If the leaving water temperature drops below 4 °C (standard value for a non-glycol unit) the machine’s antifreeze alarm is activated. If the circulating fluid is water, before the beginning of the cold season it is advisable to drain the circuit to prevent water frosting.
If the circuit cannot be drained, it is essential to avoid de-energizing the unit, so as to permit the activation, when necessary, of the frost protection.
Compressor protection
Compressors are equipped with a heating element to prevent oil dilution, which may result in remarkable risks of failure of compressors.
The windings of the compressors’ motors are provided with a thermal protection.
An accessory kit for thermal protection (ACB) is available, for any overcurrent of compressors, which shall be shop-mounted.
Flow switch
A flow switch must be installed, to prevent the unit working in case of insufficient circulation of the chilled fluid.
WARNING
The electrical flow switch must be carefully installed, according to the instructions given by the Manufacturer.
The electrical flow switch must be installed on the pressing side of the circulation pump for the fluid, just upstream of the heat exchanger’s inlet. The electrical flow switch must be installed in a horizontal straight length of piping, in a position reasonably far (both upstream and downstream) from localized pressure drops (curves, valves etc.).
26
7 - Product Description
7.1 Introduction
SyScrew Water EVO units are designed for indoor installation.
They can be equipped with one or two circuits (depending on the model) and may be used to cool water to the evaporator and / or to heat water to the condenser. When heating capacity is not the required useful effect, is is necessary to match the unit with a cooling tower or well water in order to reject condenser heat load.
VERSION
Super Low Noise version (S)
The units are suitable for indoor installation.
This series includes the following versions:
DESCRIPTION
Water cooled or air cooled (RC version) chillers operating with R134a refrigerant.
CO versions are equipped with dedicated compressors optimized for low condensing pressure.
Special Version
Brine version: units with dedicated evaporators to allow operation with brine (ethylene or propylene) temperature down to -8 °C.
Available options:
OPTIONS
Desuperheater (D)
Totaly heat recovery
DESCRIPTION
The heat recovery is carried out by a desuperheater mounted on the compressor’s discharge line.
Not available. For information, please contact commercial office.
7.2 General specifications
The units are supplied complete and provided with all connecting pipes for the refrigerant and internal wiring.
The refrigeration circuit of each unit undergoes a pressure test, is drained, vacuumised, dehydrated and filled with refrigerant, and includes the necessary oil. Once assembled, each unit is subjected to a complete final testing and the correct operation of all refrigeration circuits is checked.
The base and the frame of each unit are made of very thick galvanised sheet, and are secured by screw and stainless bolts. All panels are secured by screw and tropicalised steel bolts, they can be disassembled for easy access to internal components.
All galvanised steel parts are painted with white polyester resin, to ensure the resistance of the unit to corrosion and weather agents over time.
7.3 Compressors
The units are provided with high power, high efficiency and low vibration level semi-hermetic screw compressors (oil injection or external cooling with plate-type exchangers) to reduce the compressor’s discharge temperature (on request for special application).
The capacity control can be both of the step type (as standard) or of the stepless type (on request). It is handled by capacity control solenoid valves, handled by the microprocessor of the appliance.
The motor’s terminals are weatherproof, according to standard IP-54.
7.4 Refrigeration circuits
Units are equipped with one or two independent circuits with screw compressors and shell and tube heat exchanger.
Each refrigerant circuit includes: a service valve for refrigerant filling, shutoff valves for suction lines (on request), as well as for the delivery and liquid lines, an electronic expansion valve, that completely closed (as a solenoid valve) makes it possible to start/ stop the compressor, a dehydrating cartridge filter, a sight glass with humidity indicator.
Furthermore, each circuit is equipped with safety devices in accordance with PED 2014/68/EU: high and low pressure switches, safety valves providing protection in case of fire or malfunction of compressors.
27
7 - Product Description (continued)
7.5 Water heat exchangers
Evaporator
The units are provided with a direct-expansion refrigerant/water shell and tube heat exchanger with several refrigeration circuits.
Evaporators are insulated with flexible insulation, based on closed cell synthetic rubber in black color, 9 mm thick, highly resistant to water and to water vapour. A synthetic leather coating, 1.1 mm thick, protects the outer surface.
Condenser
All units are equipped with one or two condensers, one each circuit.
Heat exchanger is shell and tube type, arranged for ispection, cleaning and maintenance operation.
Desuperheater
All units are available with desuperheaters (DSH). DSH is refrigerant/ water heat exchanger with brazed plates.
DSH is fitted on the compressor discharge pipe and it’s dimensioned to recover about the 10% of total rejected heat. Units with a single compressor are provided with a single heat exchanger, while units with two compressors are provided with two heat exchangers, one each circuit
Total heat recovery condenser
All units are available with total heat recovery condenser (THRC).
THRC is refrigerant / water heat exchanger with brazed plates or shell and tube, according to chiller size. THRC is fitted on the compressor discharge line in series with the standard condensing circuit. Heat recovery function is enabled supplying heat recovery exchanger with water. Units with a single compressor are provided with a single heat exchanger, while units with two compressors are provided with two heat exchangers, one each circuit. Heat recovery condensers are insulated with flexible insulation, based on closed cell synthetic rubber in black color, 9 mm thick.
7.6 Electric power supply and control system
All units are provided with a microprocessor and a “Chiller Control” system.
The electrical connection of the controls and the startup units for the motor are carried out and tested in the factory. The power supply and control components are separate and accessible from different doors.
A door stop disconnecting switch is always mounted on the door of the unit. Protection level is in accordance with IP54 standard.
The power supply compartment includes:
Q
Master switch
Q Network isolator, contactors, compressor fuses
Control panel includes:
Q A transformer for auxiliaries, fuses, relay and electronic card, a thermostat for the compressor’s delivery temperature
Q The keyboard and the display of the “Chiller-Control” microcomputer, mounted on the door of the control section.
7.7 Accessories
List of available accessories, provided separately, to be mounted on site by the installer:
Water flow switch
Prevents the operation of the unit when the chilled fluid is insufficient.
It is advisablem to install a flow switch, to ensure the correct operation of the unit.
Water filter
Filter to be mounted on the suction side of the water heat exchanger.
It is mandatory to install a water filter to remove impurities from the water suplly.
Antivibrating supports (AVM)
Isolating spring supports, equipped with bolts for fastening to the base. They are supplied separated from the unit and must be mounted on site by the customer, at his own expense.
Remote wall terminal
Makes it possible to check the unit through a remote terminal, up to a maximum distance of 400 meters.
Modem GSM
Makes it possible to check the working mode or the switching on/off of the unit via SMS. In case of any alarms, the unit sends an SMS to the user.
RS-485 serial card (for MODBUS or LONWORK or BACNET)
A communication interface makes it possible to control and manage the unit from a local station, with RS485 connection, up to a distance of 1000 m.
It is possible to obtain the remote control and the management, by inserting the control into the management plant of the building.
28
7 - Product Description (continued)
Refrigerant circuit - CO/HP/BC versions
S A A
5
S
AT
7
1
H
6
S
S B
BT D
EXV
CONTROL
UNIT
CONTROL
5
2
G
E
F
4
9
3
S
E
F
8
COMPONENTS
1
2
3
4
5
6
Compressor (Screw type)
Water cooled condenser
Filter drier
Electronic expansion valve
Globe valve
Heat exchanger (Shell & Tube Type)
7 Desuperheater (Optional)
8
Water temperature sensor
(HP version only)
9 Sight glass
SAFETY / CONTROL DEVICES
A
High pressure switch 15.5 bar (CO)
19.8 bar (HP/BC)
B Low pressure switch (0.5 bar)
AT High pressure transducer
BT Low pressure transducer
D Suction temperature sensor
E Outlet water temperature sensor
F Inlet water temperature sensor
G PED pressure relief valve HP side (22 bar)
H PED pressure relief valve LP side (14.5 bar)
S Shrader connection (Service only)
Pipe connection with Shrader valve
Note: For reasons of readability, one circuit only is shown.
29
7 - Product Description (continued)
Refrigerant circuit - RC version
S
A A
5
S
AT
7
E
F
1
H
6
S
S B
BT D
EXV
CONTROL
UNIT
CONTROL
4
9
3
S
5
G
COMPONENTS
1 Compressor (Screw type)
3 Filter drier
4 Electronic expansion valve
5 Globe valve
6 Heat exchanger (Shell & Tube Type)
7 Desuperheater (Optional)
9 Sight glass
SAFETY / CONTROL DEVICES
A High pressure switch (19.8 bar)
B Low pressure switch (0.5 bar)
AT High pressure transducer
BT Low pressure transducer
D Suction temperature sensor
E Outlet water temperature sensor
F Inlet water temperature sensor
G PED pressure relief valve HP side (22 bar)
H PED pressure relief valve LP side (14.5 bar)
S Shrader connection (Service only)
Pipe connection with Shrader valve
30
8 - Technical Data
Model
990
1070
1130
1220
1280
1400
1550
700
770
860
920
440
490
570
630
8.1 Pressure drops
Evaporator Pressure drop
Nom. Capacity kW
1002
1075
1137
1227
1289
1434
1574
710
789
878
939
446
496
573
639
Qnom.
l/h
76696
85256
98502
109937
122159
135759
151049
161546
172290
184901
195575
211038
221624
246703
270809
Qmax.
l/h
127827
142094
164170
183229
203598
226266
251749
269244
287150
308168
325959
351730
369374
411172
451349
Qmin. l/h
54783
60897
70359
78527
87256
96971
107892
115390
123064
132072
139697
150742
158303
176217
193435
K kPa/(l/h)^2
7.297E-09
4.149E-09
5.354E-09
5.354E-09
2.021E-09
2.021E-09
1.824E-09
1.824E-09
1.435E-09
1.392E-09
1.392E-09
7.245E-10
7.245E-10
1.020E-09
1.020E-09
Dp nom kPa
42.6
47.6
53.2
32.3
35.6
62.1
74.8
42.9
30.2
52.0
64.7
30.2
37.2
41.6
47.6
DP max kPa
118.3
132.2
147.9
89.6
98.8
172.5
207.8
119.2
83.8
144.3
179.8
83.8
103.5
115.6
132.2
DP min kPa
21.7
24.3
27.2
16.5
18.2
31.7
38.2
21.9
15.4
26.5
33.0
15.4
19.0
21.2
24.3
Model
990
1070
1130
1220
1280
1400
1550
440
490
570
630
700
770
860
920
Condenser pressure drops
Nom. Capacity kW
676
686
774
767
592
596
601
678
853
935
846
939
522
525
530
590
680
760
Qnom.
l/h
101844
102507
103347
116541
116249
118001
133065
131888
146721
160884
91178
101472
116977
130648
145519
161566
89857
90315
Qmax.
l/h
169741
170845
172245
194234
193749
196668
221775
219813
244535
268140
151964
169120
194961
217746
242532
269276
149761
150525
Qmin. l/h
63653
64067
64592
72838
72656
73751
83166
82430
91701
100552
56987
63420
73110
81655
90949
100979
56160
56447
K kPa/(l/h)^2
6.320E-09
4.928E-09
3.997E-09
2.007E-09
2.007E-09
1.958E-09
6.320E-09
6.320E-09
4.928E-09
4.928E-09
4.928E-09
3.997E-09
3.997E-09
3.997E-09
3.138E-09
3.138E-09
1.958E-09
1.958E-09
Dp nom kPa
51.1
51.8
52.6
54.3
54.0
55.7
55.6
54.6
42.2
50.7
52.5
50.7
54.7
34.3
42.5
51.1
51.0
51.6
DP max kPa
142.0
143.8
146.2
150.8
150.1
154.6
154.3
151.6
117.1
140.8
146.0
141.0
151.9
95.2
118.0
142.0
141.8
143.2
DP min kPa
20.0
20.2
20.6
21.2
21.1
21.7
21.7
21.3
16.5
19.8
20.5
19.8
21.4
13.4
16.6
20.0
19.9
20.1
31
Desuperheater pressure drop
Model
1070
1130
1220
1280
1400
1550
440
490
570
630
700
770
860
920
990
Nom. Capacity kW
34
38
44
49
44
47
50
34
36
39
42
Qnom.
l/h
5927
6596
7603
8492
5841
6245
6663
7146
7556
8160
8573
8 - Technical Data (continued)
9734
10409
11105
11911
12594
13599
14288
Qmax.
l/h
9878
10993
12672
14154
Qmin. K l/h kPa/(l/h)^2
3704
4122
4752
5308
2.285E-08
2.285E-08
1.380E-08
1.380E-08
3650
3903 not available not available
2.285E-08
2.285E-08
4164
4466
4723
5100
2.285E-08
1.380E-08
1.380E-08
1.380E-08
5358 1.380E-08 not available not available
Dp nom kPa
0.8
1.0
0.8
1.0
0.8
0.9
1.0
0.8
0.9
1.0
0.7
2.2
2.6
2.8
2.2
2.5
2.8
2.0
DP max kPa
2.2
2.8
2.2
2.8
0.3
0.4
0.4
0.3
0.3
0.4
0.3
DP min kPa
0.3
0.4
0.3
0.4
(*) Capacity referred to only one circuit.
32
8 - Technical Data (continued)
8.2 Technical data
SyScrew Water EVO CO _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections inch
EXTERNAL HEAT EXCHANGER (CONDENSER)
Number
Type
Water connections
REFRIGERANT
Type
DESUPERHEATER inch
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION)
Shipping
Operating
DIMENSIONS (_ VERSION) inch kg kg kg kg
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height mm mm mm mm mm mm
440
6
4
2509
2690
2703
2884
3620
1350
1650
3620
1350
1750
490 570 630
400 (± 10%) / 3 / 50
1
SD
50-75-100
700 770
2538
2725
2732
2919
3620
1350
1650
3620
1350
1750
6
4
2”1/2
1
Screw
6
1
Shell & tube (Pure counterflow)
6 8
5
1
Shell & tube
5
R134a
5
1
PHE
N.A.
8
5
2701
2918
2895
3112
4210
1350
1650
4210
1350
1750
2807
3040
3001
3234
4210
1350
1650
4210
1350
1750
3185
3523
3379
3717
4180
1350
1650
4180
1350
1750
3252
3597
3446
3791
4180
1350
1650
4180
1350
1750
860
2
25-50-62-
75-87-100
2
8
2
4
5511
5966
4400
1520
1710
4650
1520
1770
2
2”1/2
5124
5579
33
8 - Technical Data (continued)
SyScrew Water EVO CO _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections inch
EXTERNAL HEAT EXCHANGER (CONDENSER)
Number
Type
Water connections
REFRIGERANT
Type
DESUPERHEATER inch
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION)
Shipping
Operating
DIMENSIONS (_ VERSION) inch kg kg kg kg
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height mm mm mm mm mm mm
920
8
4
5154
5615
5541
6002
4400
1520
1710
4650
1520
1770
990
8
4
5266
5826
5653
6213
4600
1520
1710
4650
1520
1770
1070 1130 1220
400 (± 10%) / 3 / 50
2
SD
25-50-62-75-87-100
1280
5400
5948
5787
6335
4650
1520
1710
4650
1520
1770
2
Screw
8
1
Shell & tube (Pure counterflow)
8 8 8
4 / 5 5
2
Shell & tube
5
R134a
5
2
PHE
2”1/2
5505
6055
5892
6442
4650
1520
1710
4650
1520
1770
5596
6126
5983
6513
4650
1520
1710
4650
1520
1770
5638
6175
6025
6562
4650
1520
1710
4650
1520
1770
1400
10
5
1550
10
5
6132
6793
6519
7180
5350
1520
1710
5350
1520
1770
N.A.
6227
6888
6614
7275
5350
1520
1710
5350
1520
1770
34
8 - Technical Data (continued)
SyScrew Water EVO HP _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections inch
EXTERNAL HEAT EXCHANGER (CONDENSER)
Number
Type
Water connections
REFRIGERANT
Type
DESUPERHEATER inch
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION)
Shipping
Operating
DIMENSIONS (_ VERSION) inch kg kg kg kg
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height mm mm mm mm mm mm
440
6
4
2509
2690
2703
2884
3620
1350
1650
3620
1350
1750
490 570 630
400 (± 10%) / 3 / 50
1
SD
50-75-100
700 770
2538
2725
2732
2919
3620
1350
1650
3620
1350
1750
6
4
2”1/2
1
Screw
6
1
Shell & tube (Pure counterflow)
6 8
5
1
Shell & tube
5
R134a
5
1
PHE
N.A.
8
5
2701
2918
2895
3112
4210
1350
1650
4210
1350
1750
2807
3040
3001
3234
4210
1350
1650
4210
1350
1750
3185
3523
3379
3717
4180
1350
1650
4180
1350
1750
3252
3597
3446
3791
4180
1350
1650
4180
1350
1750
860
2
25-50-62-
75-87-100
2
8
2
4
5511
5966
4400
1520
1710
4650
1520
1770
2
2”1/2
5124
5579
35
8 - Technical Data (continued)
SyScrew Water EVO HP _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections inch
EXTERNAL HEAT EXCHANGER (CONDENSER)
Number
Type
Water connections
REFRIGERANT
Type
DESUPERHEATER inch
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION)
Shipping
Operating
DIMENSIONS (_ VERSION) inch kg kg kg kg
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height mm mm mm mm mm mm
920
8
4
5154
5615
5541
6002
4400
1520
1710
4650
1520
1770
990
8
4
5266
5826
5653
6213
4600
1520
1710
4650
1520
1770
1070 1130 1220
400 (± 10%) / 3 / 50
2
SD
25-50-62-75-87-100
1280
5400
5948
5787
6335
4650
1520
1710
4650
1520
1770
2
Screw
8
1
Shell & tube (Pure counterflow)
8 8 8
4 / 5 5
2
Shell & tube
5
R134a
5
2
PHE
2”1/2
5505
6055
5892
6442
4650
1520
1710
4650
1520
1770
5596
6126
5983
6513
4650
1520
1710
4650
1520
1770
5638
6175
6025
6562
4650
1520
1710
4650
1520
1770
1400
10
5
1550
10
5
6132
6793
6519
7180
5350
1520
1710
5350
1520
1770
N.A.
6227
6888
6614
7275
5350
1520
1710
5350
1520
1770
36
8 - Technical Data (continued)
SyScrew Water EVO RC _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections
REMOTE CONDENSER CONNECTIONS
Type
Inlet refrigerant connections Circuit 1
Outlet refrigerant connections Circuit 1
Inlet refrigerant connections Circuit 2
Outlet refrigerant connections Circuit 2
REFRIGERANT inch inch inch inch inch
Type
DESUPERHEATER
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION) inch kg kg
Shipping
Operating
DIMENSIONS (_ VERSION)
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height kg kg mm mm mm mm mm mm
440
6
1.5/8”
3.1/8”
-
-
2159
2302
3620
1350
1750
2353
2496
3620
1350
1650
490 570 630
400 (± 10%) / 3 / 50
1
SD
50-75-100
700 770
2169
2312
2363
2506
3620
1350
1650
6
1.5/8”
3.1/8”
-
-
2”1/2
1
Screw
2.1/8”
3.5/8”
-
-
6
1
Shell & tube (Pure counterflow)
6 8
To be brazed
2.1/8”
3.5/8”
-
-
2.1/8”
4.1/8”
-
-
R134a
1
PHE
N.A.
8
2.1/8”
4.1/8”
-
-
2285
2456
2479
2650
4210
1350
1650
2305
2476
2499
2670
4210
1350
1650
2676
2952
2870
3146
4180
1350
1650
2716
2992
2910
3186
4180
1350
1650
3620
1350
1750
4210
1350
1750
4210
1350
1750
4180
1350
1750
4180
1350
1750
860
2
25-50-62-
75-87-100
2
8
1.5/8”
3.1/8”
1.5/8”
3.1/8”
2
2”1/2
4425
4804
4812
5191
4400
1520
1710
4650
1520
1770
37
8 - Technical Data (continued)
SyScrew Water EVO RC _ / S
Power supply
Number of refrigerant circuits
Start-up Type
V/Ph/Hz
Total capacity steps %
COMPRESSOR
Number
Type
INTERNAL HEAT EXCHANGER (EVAPORATOR)
Number
Type
Water connections
REMOTE CONDENSER CONNECTIONS
Type
Inlet refrigerant connections Circuit 1
Outlet refrigerant connections Circuit 1
Inlet refrigerant connections Circuit 2
Outlet refrigerant connections Circuit 2
REFRIGERANT inch inch inch inch inch
Type
DESUPERHEATER
Number
Type
Water connections
WEIGHT (_ VERSION)
Shipping
Operating
WEIGHT (S VERSION) inch kg kg
Shipping
Operating
DIMENSIONS (_ VERSION)
Length
Width
Height
DIMENSIONS (S VERSION)
Length
Width
Height kg kg mm mm mm mm mm mm
920
8
1.5/8”
3.1/8”
1.5/8”
3.1/8”
4435
4814
4822
5201
4400
1520
1710
4650
1520
1770
990
8
1.5/8”
3.1/8”
1.5/8”
3.1/8”
4526
4998
4913
5385
4600
1520
1710
4650
1520
1770
1070 1130 1220
400 (± 10%) / 3 / 50
2
SD
25-50-62-75-87-100
1280
4613
5071
5000
5458
4650
1520
1710
2
Screw
1.5/8”
3.1/8”
2.1/8”
3.5/8”
8
1
Shell & tube (Pure counterflow)
8 8 8
To be brazed
2.1/8” 2.1/8”
3.5/8”
2.1/8”
3.5/8”
3.5/8”
2.1/8”
3.5/8”
2.1/8”
3.5/8”
2.1/8”
3.5/8”
R134a
2
PHE
2”1/2
4673
5131
5060
5518
4650
1520
1710
4739
5170
5126
5557
4650
1520
1710
4759
5190
5146
5577
4650
1520
1710
4650
1520
1770
4650
1520
1770
4650
1520
1770
4650
1520
1770
1400
10
2.1/8”
4.1/8”
2.1/8”
4.1/8”
2.1/8”
4.1/8”
2.1/8”
4.1/8”
5073
5596
5460
5983
5350
1520
1710
5350
1520
1770
1550
10
N.A.
5153
5676
5540
6063
5350
1520
1710
5350
1520
1770
38
8 - Technical Data (continued)
8.3 Electrical data - SyScrew Water EVO CO
1070
1130
1220
1280
440
490
570
630
700
770
860
920
990
1400
1550
Model System Circuit
Compressor start mode
Nominal power input
1
2
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
2
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
95
95
108
107
83
84
94
95
(kW)
84
94
107
120
136
150
83
123
136
136
148
148
107
109
124
123
Nominal current input
Maximum power input
Maximum current input - FLA
158
158
176
175
139
141
157
158
203
227
255
139
(A)
141
157
175
207
227
227
250
250
175
177
209
207
132
132
147
147
147
147
167
167
(kW)
132
147
167
186
220
240
132
167
167
186
186
186
220
220
240
240
233
233
266
266
266
266
306
306
(A)
233
266
306
345
378
411
233
306
306
345
345
345
378
378
411
411
Start-up current
- LRA
Nominal power factor
318
318
436
436
436
436
465
465
(A)
318
436
465
586
650
805
318
465
465
586
586
586
650
650
805
805
0,87
0,86
0,87
0,87
0,87
0,87
0,89
0,89
-
0,86
0,87
0,89
0,86
0,86
0,85
0,87
0,89
0,89
0,86
0,86
0,86
0,86
0,86
0,86
0,86
Corrected power factor*
Carter oil absorbed power
(230 Vac)
300
300
300
300
300
300
300
300
300
300
300
300
(W)
300
300
300
300
300
300
300
300
300
300
300
300
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
-
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
_ S Version
Current input
Power input
Max Start-up current
UNIT (aM) FUSES
Phase WIRE SECTION
Nominal
Maximum
Nominal
Maximum
440 490 570 630 700 770 860 920 990 1070 1130 1220 1280 1400 1550
A 141 157 175 203 227 255 278 298 316 334 350 386 414 454 500
A 233 266 306 345 378 411 466 499 532 572 612 651 690 756 822 kW 84 94 107 120 136 150 167 178 190 203 215 233 245 272 296 kW 132 147 167 186 220 240 264 279 294 314 334 353 372 440 480
A 318 436 465 586 650 805 551 669 702 731 771 892 931 1028 1216 mm
A 250 315 315 400 400 500 630 630 630 630 630 800 800 800 1000
2 120 185 185 240 240 2x185 2x185 2x185 2x185 2x185 2x185 2x240 2x240 2x240 2x300
(*) Power factor correction capacitor option.
39
8 - Technical Data (continued)
Electrical data - SyScrew Water EVO HP-RC-BC
1070
1130
1220
1280
440
490
570
630
700
770
860
920
990
1400
1550
Model System Circuit
Compressor start mode
Nominal power input
1
2
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
2
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
S/D
113
113
131
130
99
99
111
113
(kW)
100
111
129
145
168
178
99
147
168
168
176
176
130
132
149
147
Nominal current input
Maximum power input
Maximum current input - FLA
183
183
220
218
165
165
181
183
242
278
300
165
(A)
166
181
217
244
278
278
297
297
218
220
246
244
144
144
161
161
161
161
188
188
(kW)
144
161
188
212
240
259
144
188
188
212
212
212
240
240
259
259
280
280
310
310
310
310
320
320
(A)
280
310
320
360
413
447
280
320
320
360
360
360
413
413
447
447
Start-up current
- LRA
Nominal power factor*
436
436
465
465
465
465
586
586
(A)
436
465
586
650
805
917
436
586
586
650
650
650
805
805
917
917
0,86
0,87
0,89
0,89
0,89
0,89
0,86
0,86
-
0,87
0,89
0,86
0,87
0,87
0,86
0,86
0,86
0,86
0,88
0,87
0,87
0,87
0,87
0,86
0,86
Corrected power factor**
Carter oil absorbed power
(230 Vac)
300
300
300
300
300
300
300
300
300
300
300
300
(W)
300
300
300
300
300
300
300
300
300
300
300
300
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
-
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
> 0.90
_ S Version
Current input
Power input
Max Start-up current
UNIT (aM) FUSES
Phase WIRE SECTION
Nominal
Maximum
Nominal
Maximum
440 490 570 630 700 770 860 920 990 1070 1130 1220 1280 1400 1550
A 166 181 217 242 278 300 330 346 366 403 436 466 488 556 594
A 280 310 320 360 413 447 560 590 620 630 640 680 720 826 894 kW 100 111 129 145 168 178 197 210 225 244 259 280,9 294 335 352 kW 155 175 204 222 254 277 310 330 350 379 408 426 444 508 554
A 436 465 586 650 805 917 716 745 775 896 906 970 1010 1218 1364 mm
A 315 315 400 400 500 500 630 630 630 800 800 800 800 1000 1000
2 185 185 240 240 2x185 2x185 2x185 2x185 2x185 2x240 2x240 2x240 2x240 2x300 2x300
(*) Data valid for HP version.
(**) Power factor correction capacitor option.
40
8 - Technical Data (continued)
8.4 Position of shock adsorbers and weight distribution on supports
SYSCREW WATER
CO/HP/BC _
990
1070
1130
1220
1280
1400
1550
700
770
860
920
440
490
570
630
F1 kg
619
634
683
746
826
849
1242
1254
1301
1325
1374
1391
1413
1397
1409
Weight distribution
F2 kg
764
773
832
861
1021
1042
1783
1791
1861
1886
1934
F3 kg
581
589
627
659
740
756
1006
1016
1052
1088
1094
1951
1970
2109
2141
1112
1117
1288
1303
F4 kg
726
729
776
774
936
949
1548
1553
1612
1649
1654
1672
1674
1999
2035
Operating weight kg
2690
2725
2918
3040
3523
3597
5579
5615
5826
5948
6055
6126
6175
6793
6888
Shipping weight kg
2509
2538
2701
2807
3185
3252
5124
5154
5266
5400
5505
5596
5638
6132
6227
P coordinates a mm
1050
1050
1050
1050
1050
1050
1220
1220
1220
1220
1220 b mm
2200
2200
2200
2200
2200
2200
2400
2400
2400
2400
2400
1220
1220
1220
1220
2400
2400
2400
2400
CG y mm
1069
1064
1057
1037
1047
1043
1099
1098
1097
1104
1089
1091
1085
1161
1163 x mm
583
581
728
727
582
579
579
565
727
725
723
722
720
738
740
SYSCREW WATER
CO/HP/BC _ S
990
1070
1130
1220
1280
1400
1550
700
770
860
920
440
490
570
630
F1 kg
651
666
716
778
858
882
1309
1321
1368
1392
1440
1457
1480
1400
1412
Weight distribution
F2 kg
F3 kg
829
838
897
926
1086
1107
1910
1918
1988
2013
2061
613
622
659
691
773
789
1073
1083
1119
1155
1160
2078
2097
2299
2332
1179
1184
1291
1306
F4 kg
791
794
840
839
1001
1014
1674
1680
1739
1776
1781
1799
1801
2190
2226
Operating weight kg
2884
2919
3112
3234
3717
3791
5966
6002
6213
6335
6442
6513
6562
7180
7275
Shipping weight kg
2703
2732
2895
3001
3379
3446
5511
5541
5653
5787
5892
5983
6025
6519
6614
P coordinates a mm b mm
1050
1050
1050
1050
1050
1050
1220
1220
1220
1220
1220
2200
2200
2200
2200
2200
2200
2400
2400
2400
2400
2400
1220
1220
1220
1220
2400
2400
2400
2400
CG y mm
1071
1067
1060
1041
1049
1046
1105
1105
1104
1110
1096
1097
1092
1163
1165 x mm
589
587
733
731
590
587
586
573
732
730
727
726
725
763
764
41
8 - Technical Data (continued)
Position of shock adsorbers and weight distribution on supports
SYSCREW WATER
RC _
990
1070
1130
1220
1280
1400
1550
700
770
860
920
440
490
570
630
F1 kg
507
513
811
810
401
402
426
429
844
842
865
866
874
823
832
Weight distribution
F2 kg
675
678
726
732
890
903
1611
1613
1676
1690
1727
F3 kg
476
478
502
506
586
593
791
794
823
846
839
1736
1749
1775
1803
849
846
1023
1035
F4 kg
750
754
802
809
969
983
1591
1597
1655
1694
1701
1719
1721
1975
2006
Operating weight kg
2302
2312
2456
2476
2952
2992
4804
4814
4998
5071
5131
5170
5190
5596
5676
Shipping weight kg
2159
2169
2285
2305
2676
2716
4425
4435
4526
4613
4673
4739
4759
5073
5153
P coordinates a mm
1050
1050
1050
1050
1050
1050
1220
1220
1220
1220
1220 b mm
2200
2200
2200
2200
2200
2200
2400
2400
2400
2400
2400
1220
1220
1220
1220
2400
2400
2400
2400
CG y mm
1172
1171
1169
1168
1159
1159
1190
1192
1190
1202
1188
1192
1187
1285
1286 x mm
661
662
813
813
650
650
653
654
813
814
815
815
816
818
819
SYSCREW WATER
RC _ S
990
1070
1130
1220
1280
1400
1550
700
770
860
920
440
490
570
630
F1 kg
540
546
878
877
433
435
458
461
911
908
931
933
941
827
835
Weight distribution
F2 kg
F3 kg
740
743
790
797
954
967
1738
1739
1803
1817
1854
619
626
858
861
508
510
535
538
890
912
905
1863
1876
1966
1994
915
913
1026
1038
F4 kg
815
818
867
874
1033
1047
1718
1723
1782
1821
1828
1845
1848
2165
2196
Operating weight kg
2496
2506
2650
2670
3146
3186
5191
5201
5385
5458
5518
5557
5577
5983
6063
Shipping weight kg
2353
2363
2479
2499
2870
2910
4812
4822
4913
5000
5060
5126
5146
5460
5540
P coordinates a mm b mm
1050
1050
1050
1050
1050
1050
1220
1220
1220
1220
1220
2200
2200
2200
2200
2200
2200
2400
2400
2400
2400
2400
1220
1220
1220
1220
2400
2400
2400
2400
CG y mm
1166
1166
1163
1163
1155
1155
1191
1193
1191
1202
1189
1192
1188
1280
1280 x mm
663
664
812
812
654
654
657
657
812
813
814
814
815
842
843
42
8 - Technical Data (continued)
8.6 Dimensional drawings - SyScrew 440-770 Water EVO RC
Front view Side view
3
775
D
4
Back view
ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
A
1
B
D
Top view
4 x 18 P2 P4
2
C
1350
P1 2200
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Liquid connection
Discharge connection
P1, P2, P3, P4 AVM position
Size A B C D dia 1-2 dia 3 dia 4
440-490 650 2410 560 3620 DN150 (6”) 1 5/8” 3 1/8”
570-630 680 2980 550 4210 DN150 (6”) 2 1/8” 3 5/8”
700-770 720 2860 600 4180 DN150 (6”) 2 1/8” 4 1/8”
43
8 - Technical Data (continued)
Dimensional drawings - SyScrew 440-770 Water EVO RC_S
Front view Side view
3
775
D
4
Back view
ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
A
1
B
D
Top view
4 x 18 P2 P4
2
C
1350
P1
2200
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Liquid connection
Discharge connection
P1, P2, P3, P4 AVM position
Size A B C D dia 1-2 dia 3 dia 4
440-490 650 2410 560 3620 DN150 (6”) 1 5/8” 3 1/8”
570-630 680 2980 550 4210 DN150 (6”) 2 1/8” 3 5/8”
700-770 720 2860 600 4180 DN150 (6”) 2 1/8” 4 1/8”
44
8 - Technical Data (continued)
Dimensional drawings - SyScrew 440-770 Water EVO CO / HP
Front view Side view
D
SIZES 440/490
Back view
SIZES 570/770
3
3
4
130
1020
1350
200
1085
1350
265
4
ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM A
1
B
D
Top view
4 x 18
P2 P4
2
C
P1
2200
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Condenser water outlet victaulic connection
Condenser water inlet victaulic connection
P1, P2, P3, P4 AVM position
Size
440-490
570
630
700-770
Size
440-490
570
630
700-770
E
130
680
680
720
A
650
680
680
720
B
2410
2980
2980
2860
C
560
550
550
600
D
3620
4210
4210
4180
F
350
2980
2980
2860 dia 1-2 dia 3-4
DN150 (6”) DN100 (4”)
DN150 (6”) DN125 (5”)
DN150 (6”) DN125 (5”)
DN200 (8”) DN125 (5”)
45
8 - Technical Data (continued)
Dimensional drawings - SyScrew 440-770 Water EVO CO / HP_S
Front view Side view
D
SIZES 440/490
Back view
SIZES 570/770
3
3
4
130
1020
1350
200 1085
1350
265
4
A
1
B
D
Top view
4 x 18
P2
P4
2
C
P1
2200
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Condenser water outlet victaulic connection
Condenser water inlet victaulic connection
P1, P2, P3, P4 AVM position
Size
440-490
570
630
700-770
Size
440-490
570
630
700-770
E
130
680
680
720
A
650
680
680
720
B
2410
2980
2980
2860
C
560
550
550
600
D
3620
4210
4210
4180
F
350
2980
2980
2860 dia 1-2 dia 3-4
DN150 (6”) DN100 (4”)
DN150 (6”) DN125 (5”)
DN150 (6”) DN125 (5”)
DN200 (8”) DN125 (5”)
46
8 - Technical Data (continued)
Dimensional drawings - SyScrew 860-1550 Water EVO RC
Front view Side view
3
150
210
455
3
4 ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
Back view
A
1
B
D
2
C
Top view
P2 4 x 18 P4
1520
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Liquid connection
Discharge connection
P1, P2, P3, P4 AVM position
P1
2400
P3
Size
860
920
990
1070
1130
1220
1280
1400
1550
A B C D dia 1-2 dia 3 dia 4
1090 2310 1000 4400 DN200 (8”) 1 5/8” 3 1/8”
1090 2310 1000 4400 DN200 (8”) 1 5/8” 3 1/8”
850 2860 890 4600 DN200 (8”) 1 5/8” 3 1/8”
850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8”
850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8”
850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8”
850 2860 940 4650 DN200 (8”) 2 1/8” 3 1/8”
830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”
830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”
47
8 - Technical Data (continued)
Dimensional drawings - SyScrew 860-1550 Water EVO RC_S
Front view Side view
3 3
150
210
455
4 ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
Back view
A
1
B
D
2
Top view
P2 4 x 18 P4
C
1520
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Liquid connection
Discharge connection
P1, P2, P3, P4 AVM position
P1
2400
P3
Size
860
920
990
1070
1130
1220
1280
1400
1550
A B C D dia 1-2 dia 3 dia 4
1170 2310 1170 4650 DN200 (8”) 1 5/8” 3 1/8”
1170 2310 1170 4650 DN200 (8”) 1 5/8” 3 1/8”
890 2860 900 4650 DN200 (8”) 1 5/8” 3 1/8”
890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8”
890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8”
890 2860 900 4650 DN200 (8”) 2 1/8” 3 1/8”
890 2860 960 4710 DN200 (8”) 2 1/8” 3 1/8”
890 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”
830 3570 950 5350 DN250 (10”) 2 1/8” 4 1/8”
48
8 - Technical Data (continued)
Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP
Front view Side view
ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
A
1
B
D
2
SIZES 860/990
3
4
Back view
SIZES 1070
1175 130
3
4
1240
1520
280
6
5
1175
130
1520
6
215
5
SIZES 1130/1550
3
4
5
1240
1520
280
6
Top view
P2 4 x 18 P4
P1
2400
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Condenser water outlet victaulic connection
Condenser water inlet victaulic connection
P1, P2, P3, P4 AVM position
C
49
8 - Technical Data (continued)
Dimensional drawings - SyScrew 860-1550 Water EVO CO / HP_S
Front view Side view
B
ELECTRICAL
POWER SUPPLY
FROM ELECTRIC
BOX BOTTOM
A
1
B
D
2
SIZES 860/990
3
Back view
SIZES 1070
1175
4
130
3
4
1175
130 215
1520
6
5
SIZES 1130/1550
3
4
5
1240
1520
280
6
5
1240
1520
280
6
Top view
P2 4 x 18 P4
P1
2400
P3
3
4
1
2
Evaporator water inlet victaulic connection
Evaporator water outlet victaulic connection
Condenser water outlet victaulic connection
Condenser water inlet victaulic connection
P1, P2, P3, P4 AVM position
C
50
8.6 Service spaces
8 - Technical Data (continued)
0.5 MT
2 MT
1 MT
1 MT
3 MT
51
9 - Maintenance
Carefully read the “Safety” section of this manual before carrying out any maintenance operations.
Operations
DANGER
DANGER
Do not discharge the refrigerant into the atmosphere while the refrigeration circuits are being drained. Use appropriate recovery equipment.
When the recovered refrigerant cannot be reused, return it to the manufacturer.
Do not throw away the waste oil of the compressor, because it contains refrigerant in solution.
The waste oil must be returned to the manufacturer.
Unless otherwise specified, the operations described below may be carried out only by a trained maintenance operator.
9.1 General requirements
Units have been designed for continuous operation, providing that they are subjected to regular maintenance, within the limits specified in this manual. Each unit must be serviced according to the programme by the User/Customer, and must be inspected at regular intervals by the personnel of one authorised Service Centers.
It is the responsibility of the User to meet these maintenance requirements and/or to enter into an agreement with one of authorised
Service Centers, so as to properly safeguard the operation of the appliance.
During the warranty period, in case of damage or failures caused by improper maintenance, manufacturer will not refund the costs incurred to repair the appliance in its original state.
The provisions of this section apply only to standard units; according to the order requirements, other documentation may be added, concerning any modifications or supplementary accessories.
9.2 Planned maintenance
Maintenance inspections must be carried out according to the program below, by a qualified person.
As a general rule, units cannot be repaired directly by the user, who shall not try to service or repair any failures or anomalies identified during daily inspections. If you are in doubt, please contact authorised
Service Centre.
Check the temperature of the leaving fluid
Check the pressure drops in the heat exchanger
Check for electric absorption
Check suction pressure and temperature
Check delivery pressure and temperature
Check the oil level in the compressor
Check that there are no gas bubbles in the liquid line
Check that the fins of the external coil are clean (if any)
Check the operation of the oil heaters
Check the remote control switches
Check the operation of the LP pressure switch
Check the operation of the HP pressure switch
Check the insulation of the heat exchanger
Check that terminals are tightened
Check that the terminals’ screws are tightened
Clean the exterior of the unit with water and soap
Check the density of the antifreeze (if any)
Check the operation of the flow switches
Check the operation of the solenoid valve
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡ ‡
‡
‡ ‡
‡
‡
‡
‡
52
9 - Maintenance (continued)
9.3 Refrigerant charge
WARNING
Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly.
If the charge is insufficient, the efficiency of the unit will be lower than expected. In the worst of cases the LP pressure switch may be activated, resulting in the halting of the unit.
In the presence of an excess charge, the condensing pressure will rise (in the worst of cases, the HP pressure switch may be activated, resulting in the stop of the equipment), and the consumption will increase as well.
WARNING
It is strictly forbidden to use the compressor as a vacuum pump to drain the plant.
Fill the refrigeration circuit after it has been drained for maintenance purposes (leaks, replacement of the compressor etc.). The amount of the charge is indicated on the plate affixed to the unit.
Before refilling, it is important to drain and de-hydrate the circuit, thus obtaining a minimum abs. pressure value of 0.06 mbar.
Inject the refrigerant fluid before removing the vacuum, then fill the circuit up to 90% of the total gas requirement (in liquid form). The appliance must be filled through the filling valve on the liquid line, on the outlet side of the condenser.
It is recommended to connect the refrigerant cylinder to the filling valve on the liquid line, and to arrange it in such a way as to inject only liquid refrigerant.
Then start the compressor and let the gas flow from the cylinder, up until the liquid flow, which can be observed through the sight glass, is limpid.
9.4 Compressor
Compressors are delivered with the necessary charge of lubricating oil. During normal operation, this charge is sufficient for the whole life of the unit, providing that the efficiency of the refrigeration circuit is satisfactory and if it has not been overhauled.
If the compressor needs to be replaced (following a mechanical failure or if burnt), contact one of manufacturer.
WARNING
Compressors use polyester oil. During maintenance operations on the compressor, or if you have to open the refrigerant circuit in any point, remember that this type of oil is highly hygroscopic, and accordingly it is important that it is not left exposed to the weather for prolonged periods, as this would require the replacement of the oil.
9.5 Condenser
Check at regular intervals that the water side of the heat exchanger is perfectly clean. To do this, measure the pressure drop, water side or measure the temperature of the liquid leaving and entering the heat exchanger, and compare it to the condensing temperature..
To obtain an effective heat exchange, the difference between the temperature of the leaving water and the saturated condensing temperature must be in the 3 - 5°C range. A greater difference would indicate a low efficiency of the heat exchanger (i.e. the heat exchanger is dirty).
In this case, the heat exchanger must be subjected to chemical cleaning, an operation that shall be carried out by authorised engineers.
For other maintenance operations (extraordinary overhauling, replacement of the heat exchanger etc.), contact an authorised
Service Centre.
9.6 Dehydrating filter
The refrigeration circuits are provided with dehydrating filters.
The filter clogging is marked by the presence of air bubbles in the sight glass, or by the difference between the temperatures measured downstream from and upstream of the drying filter. If, once the cartridge has been cleaned, there are still some air bubbles, the appliance has lost a part of the refrigerant charge in one or more points, that must be identified and serviced.
WARNING
If the compressor had to be replaced (due to burning of the winding or to mechanical failure), please contact one of the Authorized
Service Centers.
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9 - Maintenance (continued)
9.7 Sight glass
The sight glass is used for inspecting the refrigerant flow and the humidity % of the refrigerant. The presence of bubbles indicates that the dehydrating filter is clogged or the charge insufficient.
A colour indicator is positioned inside the sight glass. If you compare the colour of the indicator to the scale on the ring of the sight glass, you can calculate the percentage of humidity of the refrigerant. If it is excessive, replace the filter’s cartridge, operate the appliance for
1 day and then check the humidity % again. When the humidity % is within the pre-determined range, no other operations are required. If the humidity % is still too high, replace the dehydrating filter again, start the unit and operate it for another day.
9.8 Electronic expansion valve
The circuit of the unit is equipped with electronic expansion valve.
The valve is calibrated for an overheating of 6 °C.
Procedure to check for overheating:
– Measure the suction pressure with the pressure gauges on the board of the unit o using a pressure gauge connected to the service valve on the suction side.
– From the pressure gauge’s temperature scale, measure the saturated suction temperature (Tsa) which corresponds to the pressure value.
– Using a contact pressure gauge affixed to the outlet fitting of the gas of the evaporator, measure the actual temperature (Tse).
Overheating calculation (S):
S = Tse - Tsa
Overheating is regulated through the expansion valve.
If the electronic expansion valve cannot be regulated, it is probably broken, and shall be replaced. The replacement must be carried out by a Service Centre.
9.9 Evaporator
Check at regular intervals that the water side of the heat exchanger is perfectly clean. To do this, measure the pressure drop, water side
(see Section 8) or measure the temperature of the liquid leaving and entering the heat exchanger, and compare it to the evaporation temperature.
To obtain an effective heat exchange, the difference between the temperature of the leaving water and the saturated evaporating temperature must be in the 2 - 4 °C range. A greater difference would indicate a low efficiency of the heat exchanger (i.e. the heat exchanger is dirty).
In this case, the heat exchanger must be subjected to chemical cleaning, an operation that shall be carried out by authorised engineers.
For other maintenance operations (extraordinary overhauling, replacement of the heat exchanger etc.), contact an authorised
Service Centre.
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10 - Troubleshooting
The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of authorised Service Centre for technical assistance.
Anomaly
The unit continues to work, but without cooling
Ice on the suction line
Excessive noise
Low oil level in the compressor
One or both compressors are not working
Activation of the LP alarm, stop of the unit
Cause
Insufficient charge of refrigerant.
The dehydrating filter is clogged.
Wrong calibration of overheating.
Vibration of lines.
Whistler emitted by the thermostatic expansion valve.
Noisy compressor.
One or more gas or oil leaks in the circuit.
Mechanical failure of the compressor.
Anomaly of the oil heater of the compressor’s base.
Breaking of the electric circuit.
Intervention of the HP pressure switch.
The fuse of the control circuit is broken.
Loosened terminals.
Halt caused by thermal overload of the electric circuit.
Wrong wiring.
The line voltage is too low.
Short-circuit of the compressor’s motor.
Seized compressor.
Gas leak.
Insufficient charge.
Failure of the pressure switch.
Failure of the pressure switch.
Activation of the HP alarm, stop of the unit
The delivery valve is partially closed.
Substances with condensable gases in the circuit.
The fan of the condenser is stopped.
The liquid line is too hot Insufficient charge.
The valve of the liquid line is partially closed.
Frosting of the liquid line
The liquid filter is clogged.
Operation
Refill.
Replace.
Increase overheating.
Check the charge.
Check the clamping brackets, if any.
Refill.
Check the dehydrating filter.
Seized bearings; replace the compressor.
Check that the compressor’s locknuts are tightened.
Identify and remove leaks.
Request the intervention of a Service Centre.
Check the electric circuit and the resistor of the heater of the motor base, and replace defective components.
Check the electric circuit and detect any ground dispersions and short circuits. Check fuses.
Reset the pressure switch and the control panel and restart the appliance. Identify and remove the cause that enabled the pressure switch.
Check for ground dispersions and short circuits. Replace fuses.
Check and tighten.
Check the operation of check and safety devices. Identify and remove the cause.
Check wiring of check and safety devices.
Check voltage. If problems regard the system, solve them. If they are caused by the distribution network, inform the Energy
Distributor.
Check the continuity of the winding.
Replace the compressor.
Identify and remove the leak.
Refill.
Replace the pressure switch.
Check the operation of the pressure switch, replace it if defective.
Open the valve and replace it, if faulty.
Drain the circuit.
Check cables and motor. If defective, repair or replace.
Identify and remove the cause of the loss of charge and refill.
Check that valves are open.
Replace the cartridge or the filter.
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11 - Spare Parts
11.1 Spare part list
The table below shows the list of spare parts recommended during the first two years of operation.
Component
HP pressure switch
LP pressure switch
Gas filter
Electronic expansion valve
Auxiliary relays
Compressor’s fuses
Auxiliary fuses
Set of compressor contactors
Water sensor
Electronic card
Keyboard
Compressor oil resistor
11.2 Oil for compressors
The compressors are lubricated with Ester oil BSE 170 (Viscosity of
170 St / 40 °C).
11.3 Wiring diagrams
The wiring diagrams are installed inside the doors of the electrical panels of the unit. Any request for wiring diagrams shall be forwarded to manufacturer’s Service Centre.
Number
2 / 4
2 / 4
1 / 2
1 / 2
2
3 / 6
6
1
2
1
1
1 / 2
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DANGER
DANGER
12 - Dismantling, Demolition and Scrapping
During the draining of the refrigeration circuits, do not let the refrigerant overflow in the surrounding atmosphere.
The circuit must be drained using suitable recovery equipment.
Do not disperse the waste oil of the compressors in the environment, since it contains some dissolved refrigerant.
For the disposal, contact the competent authority for information.
Unless otherwise specified, the maintenance operations listed below may be carried out by any trained maintenance operator.
12.1 Generalities
Open each line that supplies the unit, including the ones of control circuits. Make sure that all disconnecting switches are secured in the off position. The power cables can be disconnected and disassembled. Refer to Chapter 4 for the position of connection points.
Remove all the refrigerant from the refrigeration circuits of the unit and store it in suitable containers, using a recovery unit. If its characteristics have remained the same, the refrigerant can be used again. Contact the competent authority to obtain information about disposal. In NO event shall the refrigerant be discharged into the atmosphere. The oil in each refrigeration circuit must be drained and collected into a suitable container; then it shall be disposes of in conformity with local regulations that apply to the disposal of waste lubricants. Any oil spillage must be recovered and disposed of in like manner.
Isolate the unit’s heat exchangers from the external hydraulic circuits and drain the heat exchange sections of the plant.
DANGER
If no shutoff valves have been provided, it may be necessary to drain the whole plant.
If a glycoled solution or a similar fluid has been used in the hydraulic circuits, or if chemical additives have been added to the circulating water, the circulating fluid MUST be drained in a proper way.
For NO reason shall a circuit containing glycoled water or a similar solution be discharged directly into the drains or surface waters.
After draining operations, the piping of the hydraulic networks can be disconnected and disassembled.
Once they have been disconnected as specified, the packaged units can be disassembled in a single piece. First of all, disassemble the anchoring screws and then lift the unit from the position of installation, and hook it to the lifting points provided, using suitable lifting equipment.
To this end, refer to Chapter 4 for the installation of these appliances, to Chapter 8 for their weights and Chapter 3 for handling.
The units that, once disconnected, cannot be removed in a single piece, must be dismantled on site; in this case, be very careful with the weight and handling of every single component.
It is always advisable to dismantle the units following the installation steps, but in reverse.
DANGER
Some residues of oil, glycoled water or similar solutions may remain in certain parts of the unit. These residues must be recovered and disposed of according to the procedures specified above.
It is very important to ensure that, while a component of the unit is being removed, all the others are properly supported.
DANGER
Use only lifting means of adequate capacity.
Once disassembled, the components of the unit can be disposed of in conformity with current regulations.
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Notes
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